Service Bulletin - Marine Parts Express
Contents
1. loss of shift control which could result in personal injury What will Mercury Marine do Mercury Marine through an authorized dealer will inspect and if necessary replace the shift link without charge What should you do Please contact your authorized Mercury Outboard dealer and mention Service Bulletin 2008 08 to schedule an appointment to have your engine shift link inspected and replaced if necessary To locate your nearest authorized Mercury Outboard dealer please use the Dealer Locator in the Mercury Marine website http northamerica mercurymarine com qualifiedservice If you do not have access to the internet please call Mercury Outboard Customer Service at 1 920 929 5040 to locate your nearest authorized Mercury Outboard dealer Please present this notice to your dealer when you bring your boat engine in for service appointment What if you have other questions or if you no longer own this engine Please contact your Mercury Outboard dealer or call Mercury Outboard Customer Service at 1 920 929 5040 between 7 30 a m and 5 30 p m CST We have sent this notice in the interest of your continued satisfaction with our product and we sincerely regret any inconvenience this may cause you Thank you for boating with Mercury Marine Mercury Marine Service2. PFERCURY MARINER Service Bulletin Bulletin No 2008 08 OEM No 2008 07 Circulate to L Sales Manager L Accounting service Manager Technician V Parts Manager Official Recall Notification U S Federal Boat Safety Act Shift Link 2 5 Liter Models Affected Models Covered Serial Number Mercury Mariner 135 150 175 OptiMax 2 5 Liter 1B692800 1B 19209 150 200 EFI 2 5 Liter THE INFORMATION IN THIS DOCUMENT IS CONFIDENTIAL AND PROTECTED BY COPYRIGHT AND IS THE PROPERTY OF MERCURY MARINE This document is provided for the sole and exclusive use of the original recipient as prescribed by Mercury Marine and may not be distributed or copied digitally or otherwise without the prior written consent of Mercury Marine 2008 08 SEPTEMBER 2008 2008 Mercury Marine Page 1 5 Official Recall Notification U S Federal Boat Safety Act Shift Link 2 5 Liter Situation Some shift links may have insufficient weld penetration between the link and shift cable and upper shift shaft attaching studs This could result in possible stud breakage and loss of shift control a Shift latch nut tighten until one I Shift link nut to upper shift shaft thread on shift link stud is exposed tighten and back off 1 4 turn above nut j Shift link washer to upper shift shaft b Shift latch washer k Guide block c Shift latch Guide block spring d Wear plate m Shift link e Anchor bracket screw 3 n Shift link bus
3. he shift link 5 Using a mirror and flashlight and or feeling with your fingers determine if the weld on the shift link directly below the stud is good or bad See instructions with photo below 6 If a good weld is found no further action is required 4 vk 37914 a A good weld will appear or feel as a raised bump directly below the stud on the bottom side of the shift link b A bad weld will appear or feel indented directly below the stud on the bottom side of the shift link Correction If a bad weld is found replace the shift link using the following steps 2008 08 SEPTEMBER 2008 2008 Mercury Marine Page 3 5 Official Recall Notification U S Federal Boat Safety Act Shift Link 2 5 Liter e Remove the port bottom cowl See the appropriate service manual for details e Disconnect the throttle cable from the throttle arm and remove the cable barrel from the anchor bracket e Disconnect the shift cable and remove the cable barrel from the anchor bracket e Remove the nut and washer that retains the shift latch and remove the latch and wear plate Retain for reassembly e Remove the three screws that retain the shift and throttle anchor bracket to the cylinder block and remove the bracket NOTE The shift switch does not need to be removed or disconnected Gently hang the bracket by the shift switch wires 137918 e Remove the guide block and spring from the shift link and retain for reassembly e Remove
4. hing to upper shift shaft f Anchor bracket o Wave washer g Shift and throttle cable barrel cup p Upper shift shaft h Barrel latch Bsn OOOO S a o ET E A E T THE INFORMATION IN THIS DOCUMENT IS CONFIDENTIAL AND PROTECTED BY COPYRIGHT AND IS THE PROPERTY OF MERCURY MARINE This document is provided for the sole and exclusive use of the original recipient as prescribed by Mercury Marine and may not be distributed or copied digitally or otherwise without the prior written consent of Mercury Marine Page 2 5 2008 Mercury Marine SEPTEMBER 2008 2008 08 Official Recall Notification U S Federal Boat Safety Act Shift Link 2 5 Liter Dealer OEM Inventory Dealer OEM inventory of affected engines should be inspected and or corrected prior to customer delivery Rework Identification If there is a green or white paint dot or mark on the shift cable latch the engine has already been reworked No further action is required 37913 a Paint dot or mark on shift latch Inspection 1 Remove the top cowl 2 Locate the shift cable latch on the anchor bracket on the port side of the engine 3 Check for a paint mark on the shift latch If a paint mark is present the engine has already been reworked and no further action is required 4 Ifno paint mark is present on the shift latch shift the engine into reverse while rotating the propeller shaft Shifting into reverse will make it easier for inspection and or removal of t
5. or replaced Warranty Mercury Marine will credit the dealer for the cost of parts and labor Complete a Parts and Accessories warranty claim listing e Outboard engine serial number e Labor 0 2 hours for inspection only e Warranty flat rate code SBO2 for inspection of shift link or e Labor 1 0 hour for inspection and replacement of shift link e Warranty flat rate code SB10 for inspection and replacement e Qty 1 shift link part number 67073A03 e Part code 223 e Failure code 40 US AND CANADA Complete and process the claim via MercNET or return a warranty claim form International Follow instructions issued by the Marine Power International office or by an authorized Marine Power Distributor 2008 08 SEPTEMBER 2008 2008 Mercury Marine Page 5 5 Official Notification of Federal Boat Safety Act Recall Dear Mercury Outboard Owner Thank you for your purchase of a Mercury 2 5 Liter OptiMax or EFI outboard engine Mercury Marine is dedicated to providing superior product reliability and customer satisfaction As part of our commitment to superior customer satisfaction we have determined that it is necessary to have your engine shift linkage inspected to ensure the reliability of your Mercury Outboard What is the condition Mercury Marine has identified a potential for insufficient weld penetration between the shift link bracket and shift cable attaching studs This could result in possible stud breakage and
6. the nut and washer that retains the shift link to the upper shift shaft and remove the shift link e Remove the bushing and wave washer from the shift link and retain for reassembly e Reassemble in the order shown on page 2 e Tighten the locknut that retains the shift link to the upper shift shaft assembly and back off 1 4 turn from snug e Place the guide block spring and guide block over the stud on the shift link e Fasten the anchor bracket to the cylinder block and tighten to the specified torque Make sure the guide block is positioned in the anchor bracket slot with the pin facing forward e Install the wear plate and shift latch e Tighten the shift latch nut until one thread on the shift link stud is exposed above the nut e Mark the shift latch with a green or white paint dot to show that it has been reworked Page 4 5 2008 Mercury Marine SEPTEMBER 2008 2008 08 Official Recall Notification U S Federal Boat Safety Act Shift Link 2 5 Liter Anchor bracket screw 3 18 180 a Shift latch nut one thread c Wear plate exposed d Guide block pin b Shift latch Parts Required Description Part Number Shift link 67073A03 Owner Notification All registered owners within the affected serial number range will receive a letter from Mercury Marine This letter will explain the situation and request that they contact their local dealer to schedule an appointment to have the shift link inspected and
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